WO2015053937A1 - Procédé pour fabriquer un matériau céramique contenant du silicium cristallin - Google Patents

Procédé pour fabriquer un matériau céramique contenant du silicium cristallin Download PDF

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WO2015053937A1
WO2015053937A1 PCT/US2014/057091 US2014057091W WO2015053937A1 WO 2015053937 A1 WO2015053937 A1 WO 2015053937A1 US 2014057091 W US2014057091 W US 2014057091W WO 2015053937 A1 WO2015053937 A1 WO 2015053937A1
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silicon
preceramic polymer
particles
polymer material
dopant particles
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PCT/US2014/057091
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Andi M. LIMARGA
Paul Sheedy
Wayde R. Schmidt
Douglas M. Berczik
Tania Bhatia Kashyap
Mark A. Hermann
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United Technologies Corporation
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Priority to EP14852865.6A priority Critical patent/EP3055270B1/fr
Priority to US15/027,705 priority patent/US9908818B2/en
Publication of WO2015053937A1 publication Critical patent/WO2015053937A1/fr

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Definitions

  • This disclosure relates to silicon-containing ceramic materials.
  • Silicon- containing ceramic materials are known and used in articles that are subject to relatively severe conditions, such as gas turbine engine components. These ceramic materials can be fabricated using one of various known ceramic processing techniques.
  • One technique is known as polymer infiltration and pyrolysis ("PIP").
  • PIP polymer infiltration and pyrolysis
  • the PIP technique involves a thermal conversion of a silicon-based polymer material to a ceramic char under a controlled atmosphere.
  • a method for providing a crystalline ceramic material includes providing a silicon-containing preceramic polymer material that can be thermally converted to one or more crystalline polymorphs.
  • the silicon- containing preceramic polymer material includes dispersed therein an effective amount of dopant particles.
  • the silicon-containing preceramic polymer material is then thermally converted to the silicon-containing ceramic material.
  • the effective amount of dopant particles enhance the formation of at least one of the one or more crystalline polymorphs, relative to the silicon-containing preceramic polymer without the dopant particles, with respect to at least one of formation of a selected polymorph of the one or more crystalline polymorphs formed, an amount formed of a selected polymorph of the one or more crystalline polymorphs formed, and a temperature of formation of the one or more crystalline polymorphs.
  • the dopant particles are carbon-containing particles.
  • the carbon- containing particles are alpha silicon carbide.
  • the carbon- containing particles are selected from the group consisting of boron carbide, nano-diamond, graphite, graphene, activated carbon, carbon nanotubes, and combinations thereof.
  • the dopant particles are nitride particles.
  • the nitride particles are selected from the group consisting of aluminum nitride, gallium nitride, boron nitride, silicon nitride, and combinations thereof.
  • the silicon- containing ceramic material is silicon carbide.
  • the silicon- containing ceramic material is a silicon-carbon ceramic compound including an element selected from the group consisting of nitrogen, boron, oxygen and combinations thereof.
  • the silicon- containing preceramic polymer material includes, by weight, up to 40% of the dopant particles.
  • the silicon- containing preceramic polymer material includes, by weight, up to 20% of the dopant particles.
  • the silicon- containing preceramic polymer material includes, by weight, up to 10% of the dopant particles.
  • the silicon- containing preceramic polymer material includes, by weight, up to 5% of the dopant particles.
  • the silicon- containing ceramic material is silicon carbide
  • the silicon-containing preceramic polymer material includes, by weight, up to 10% of the dopant particles
  • the dopant particles are silicon carbide
  • the silicon-containing preceramic polymer material is disposed within pores of a silicon carbide fiber structure.
  • a method for enhancing crystallinity and limiting thermal damage in formation of a reinforced silicon-containing ceramic material includes providing a porous structure and a silicon-containing preceramic polymer material.
  • the silicon-containing preceramic polymer material is thermally convertible into a silicon-containing ceramic material, wherein a percent crystallinity of the silicon-containing ceramic material is a function Fl of a temperature and time at which the silicon-containing preceramic polymer material is thermally converted.
  • a degree of thermal damage to the porous structure is a function F2 of the temperature and the time at which the silicon-containing preceramic polymer material is thermally converted.
  • the silicon- containing preceramic polymer material is provided with dopant particles dispersed therein to shift upwards the function Fl of the percent crystallinity.
  • the pores of the porous structure are infiltrated with the silicon-containing preceramic polymer material having the dopant particles dispersed therein, and the silicon-containing preceramic polymer material is thermally converted, at the temperature and given time, to a crystalline silicon-containing ceramic material.
  • the dopant particles are carbon-containing particles.
  • the dopant particles are nitride particles.
  • the silicon- containing preceramic polymer material includes, by weight, up to 10% of the dopant particles.
  • a method for providing a crystalline ceramic material includes providing a silicon-containing preceramic polymer material that is thermally convertible to one or more of multiple crystalline polymorphs including a first crystalline polymorph and a second crystalline polymorph.
  • the silicon- containing preceramic polymer material includes dispersing therein crystal-specific dopant particles predominantly having the first crystalline polymorph, and thermally converting the silicon-containing preceramic polymer material to a silicon-carbon ceramic material.
  • the crystal-specific dopant particles enhances, relative to the silicon-containing preceramic polymer without the crystal-specific dopant particles, the formation of the silicon-carbon ceramic matrix in the first crystalline polymorph.
  • the silicon- carbon ceramic material is silicon carbide
  • the first crystalline polymorph is an alpha polymorph of silicon carbide
  • the second crystalline polymorph is a beta polymorph of silicon carbide
  • the crystal-specific dopant particles are silicon carbide particles predominantly having the alpha polymorph.
  • Figure 1 illustrates a graphical representation of the shifting effect on crystallinity of dopant particles in a preceramic polymer.
  • Silicon-containing ceramic material can be used as a monolithic body or in a composite with other materials.
  • a ceramic matrix composite can include the silicon-containing ceramic material as a matrix with respect to a dispersed phase or structure, such as a porous body or fiber structure.
  • Silicon-containing ceramic materials can be used in a particular article for good performance in severe conditions, structural stability and thermal conductivity. These properties are tied to the microstructure of the silicon-containing ceramic material, and thus are also tied to the processing of the preceramic polymer that yields the microstructure.
  • silicon-containing ceramic materials can be polymorphic. The polymorphism, and more specifically the type of crystalline polymorph and percentage of the crystalline polymorph, controls the properties of the ceramic material.
  • one challenge in fabricating the silicon-containing ceramic material is that the polymorphic microstructure of silicon-containing ceramic materials is sensitive to the thermal conversion conditions of the preceramic polymer with respect to temperature and time. Thus, factors that limit the thermal conversion conditions can ultimately debit the properties of the silicon-containing ceramic material. For example, given thermal conversion conditions that produce good properties of the silicon-containing ceramic material can thermally damage a dispersed phase or structure in the silicon-containing ceramic material, resulting in lower properties of the dispersed phase or structure. Thus, the thermal conversion conditions are selected to strike an acceptable balance between properties of the ceramic material and the properties of the dispersed phase or structure.
  • An example method for providing a crystalline silicon-containing ceramic material includes providing a silicon-containing preceramic polymer material that can be thermally converted to one or more crystalline polymorphs.
  • the thermal conversion can be conducted in a controlled environment, such as under vacuum or under a blanket flow of argon, for example.
  • the silicon-containing preceramic polymer material is selected in accordance with the desired silicon-containing ceramic material.
  • the preceramic polymer can be a silicon-based polymer that is convertible to a silicon-carbon ceramic material.
  • silicon-carbon ceramic materials can include, but are not limited to, silicon carbide (SiC) and silicon-carbon ceramic compounds having one or more elements of nitrogen, boron and oxygen.
  • the ceramic material can be silicon oxycarbide, silicon carbonitride, silicon borocarbonitride or other combinations of silicon and carbon with boron, nitrogen and oxygen.
  • the silicon-containing preceramic polymer material includes mixed therein an effective amount of dopant particles.
  • the dopant particles enhance formation of at least one of the one or more crystalline polymorphs, relative to the silicon-containing preceramic polymer without the dopant particles, with respect to at least one of:
  • the dopant particles can serve one or more functions related to seeding the preceramic polymer material to preferentially form a selected polymorph of the one or more crystalline polymorphs formed, seeding the preceramic polymer material to form more of a selected polymorph of the one or more crystalline polymorphs, and reducing a temperature of formation of the one or more crystalline polymorphs.
  • the dopant particles enhance formation of at least one of the one or more crystalline polymorphs by lowering the thermal activation energy for crystal nucleation of the one or more crystalline polymorphs and/or increasing diffusion and crystal growth of nucleated crystals.
  • crystal nucleation can initiate at lower temperatures using the dopant particles.
  • the dopant particles are crystal-specific and predominantly have a crystalline structure corresponding to one or more crystalline polymorphs of the silicon-containing ceramic material.
  • the dopant particles function as seeds in the preceramic polymer such that upon thermal conversion, the formed ceramic material preferentially adopts the crystalline structure of the dopant particles.
  • the dopant particles, and more specifically the crystalline structure of the dopant particles can correspond to a selected one of the crystalline polymorphs of the ceramic material that can be produced in the temperature regime of the thermal conversion.
  • the composition and crystalline structure of the dopant particles can thus be selected in accordance with the crystalline polymorphs of the ceramic material that can be produced in the temperature regime of the thermal conversion.
  • the dopant particles are silicon carbide particles that are predominantly alpha polymorph of silicon carbide.
  • the silicon-containing preceramic polymer material without any dopant particles, tends to form a beta polymorph of silicon carbide.
  • dopant particles that are predominantly alpha polymorph of silicon carbide function as seeds such that upon thermal conversion, the formed silicon carbide adopts the alpha polymorph crystalline structure of the dopant particles, although some beta polymorphs of silicon carbide can also form. That is, the silicon carbide particles that are predominantly alpha polymorph of silicon promote the formation of alpha silicon carbide over beta silicon carbide.
  • the dopant particles promote formation of a selected polymorph and also increase the amount of the selected polymorph formed.
  • alpha and beta can correspond, respectively, to a hexagonal crystal structure and cubic or diamond cubic crystal structure of silicon carbide, or can alternatively refer to first and second crystalline polymorphs in other ceramic materials or in silicon carbide.
  • the dopant particles enhance formation of at least one of the one or more crystalline polymorphs, relative to the silicon-containing preceramic polymer without the dopant particles, with respect to a temperature of formation of the one or more crystalline polymorphs.
  • Example dopant particles that can alter, or reduce, a temperature of formation of the one or more crystalline polymorphs include, but are not limited to, boron-containing particles, carbon-containing particles, nitride particles, oxide particles or combinations thereof.
  • the carbon-containing particles can be silicon carbide, boron carbide (B 4 C), nano-diamond, graphite, graphene, activated carbon, carbon nanotubes, or combinations thereof.
  • the nitride particles can be aluminum nitride (A1N), gallium nitride (GaN), silicon nitride (Si 3 N 4 ), and boron nitride (BN).
  • the oxide particles can include zinc oxide (ZnO).
  • the amount of dopant particles that is sufficient to enhance formation of at least one of the one or more crystalline polymorphs can vary depending upon the selected dopant particles, selected silicon-containing preceramic polymer and time, temperature, and atmosphere of the thermal conversion, all of which can be determined experimentally given the teachings of this disclosure.
  • the preceramic polymer includes up to about 40% by weight of the dopant particles.
  • the dopant particles can affect properties of the ceramic material in ways other than enhancing formation of at least one of the one or more crystalline polymorphs.
  • the dopant particles can influence environmental stability, serve as reinforcement or both, which may or may not be desired.
  • lower dopant amounts are used.
  • the amount of dopant particles in the preceramic polymer can be less than 20%, less than 10%, or even less than 5% to reduce or limit other property contributions of the dopant particles.
  • the amount of dopant particles in the preceramic polymer is 0.05-1% to enhance formation of at least one of the one or more crystalline polymorphs without substantially providing a reinforcement contribution or affecting other properties of the ceramic material.
  • the upper limit of the amount of dopant particles that can be used in the preceramic polymer can relate to the viscosity of the preceramic polymer precursor.
  • the dopant particles increase the viscosity of the preceramic polymer precursor and thus can limit flow of the preceramic polymer, such as infiltration flow into a porous structure or fiber structure in a polymer infiltration and pyrolysis process.
  • the viscosity can be reduced by the addition of a compatible solvent to the preceramic polymer or by addition of a lower molecular weight version of the same or different polymer, for example.
  • the lower end of the range of dopant particles can be determined by the enhancement effect on formation of at least one of the one or more crystalline polymorphs.
  • the preceramic polymer free of any dopant particles, can be converted to a ceramic material under a given temperature and time to determine a baseline microstructure that can then be compared to one or more samples that contain dopant particles in selected amounts, to determine a minimum amount of dopant particles to obtain a desired effect.
  • the minimum amount of dopant particles can be determined by analytical methods including X- ray scattering techniques.
  • the effective amount of dopant particles is the amount needed to cause an increase of at least 1 % in crystallinity over the baseline under a given thermal conversion temperature and time.
  • the preceramic polymer is used in combination with one or more other materials in a composite structure.
  • An example composite structure is a ceramic matrix composite wherein the ceramic material formed from the preceramic polymer serves as a matrix with respect to a dispersed phase or structure.
  • the dispersed phase or structure can include, but is not limited to, porous bodies and fiber structures.
  • An example fiber structure is a woven or non-woven fiber structure, but other fiber structures could also be used.
  • a fiber structure of silicon carbide fibers is useful in gas turbine engine articles.
  • Some dispersed phases or structures are sensitive to the thermal conversion conditions of the preceramic polymer. For example, a conversion temperature above 1600°C is needed to convert certain preceramic polymers to predominantly crystalline silicon carbide, but such a temperature thermally damages many commercially available silicon carbide fibers. Thermal damage can manifest as evaporative loss, chemical reaction or reduction in properties, such as fiber strength. In this regard, the dopant particles also enable mitigation of thermal damage to fibers or other dispersed phases or structures.
  • Figure 1 shows a graphical representation of a shifting effect of the dopant particles on the thermal conversion of the preceramic polymer.
  • the percent crystallinity of the ceramic material, without any dopant particles is a function, represented at Fl, of a temperature and time at which the silicon-containing preceramic polymer material is thermally converted. Generally, for a given time, percent crystallinity increases with increased temperature.
  • the thermal damage to dispersed phases or structures, such as silicon carbide fibers is also a function, represented at F2, of the temperature and time at which the silicon-containing preceramic polymer material is thermally converted. Generally, for a given time, thermal damage increases with increased temperature. Thus, for a selected conversion temperature and time, there is a balance between the percent crystallinity and the degree of thermal damage.
  • the dopant particles shift upwards the function Fl of the percent crystallinity to the line represented at Fl'.
  • the percent crystallinity increases in comparison to the percent crystallinity without the dopant particles.
  • the dopant particles provide a new balance between percent crystallinity and thermal damage. For instance, at a given temperature and time, a higher degree of crystallinity can be obtained at an equivalent amount of thermal damage. Alternatively, an equivalent percent crystallinity can be obtained at a lower temperature (i.e., 1500°C or less versus 1600°C or greater), with less thermal damage, or a greater crystallinity can be obtained at a higher temperature, with equivalent thermal damage.
  • silicon-containing ceramic materials having increased crystallinity and in turn better properties, can be obtained.
  • better properties can be obtained through increased crystallinity and/or reduction in thermal damage to the dispersed phases or structures.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Ceramic Products (AREA)

Abstract

L'invention porte sur un procédé de fabrication d'un matériau céramique cristallin. Dans un exemple, le procédé comprend la fourniture d'un matériau polymère pré-céramique contenant du silicium, qui peut être thermiquement converti en un ou plusieurs polymorphes cristallins. Le matériau polymère pré-céramique contenant du silicium contient, dispersée, une quantité efficace de particules dopantes. Le matériau polymère pré-céramique contenant du silicium est ensuite thermiquement converti en le matériau céramique contenant du silicium. La quantité efficace de particules dopantes renforce la formation d'au moins l'un du ou des polymorphes cristallins, par rapport au polymère pré-céramique contenant du silicium sans les particules dopantes, pour ce qui d'au moins l'une de la formation d'un polymorphe sélectionné du ou des polymorphes cristallins formés, d'une quantité formée d'un polymorphe sélectionné du ou des polymorphes cristallins formés, et d'une température de formation du ou des polymorphes cristallins.
PCT/US2014/057091 2013-10-08 2014-09-24 Procédé pour fabriquer un matériau céramique contenant du silicium cristallin WO2015053937A1 (fr)

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EP14852865.6A EP3055270B1 (fr) 2013-10-08 2014-09-24 Procédé pour fabriquer un matériau céramique contenant du silicium cristallin
US15/027,705 US9908818B2 (en) 2013-10-08 2014-09-24 Method for providing crystalline silicon-containing ceramic material

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EP3055270A1 (fr) 2016-08-17
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EP3055270A4 (fr) 2017-07-05
US20160236986A1 (en) 2016-08-18

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